(navigation image)
Home American Libraries | Canadian Libraries | Universal Library | Community Texts | Project Gutenberg | Children's Library | Biodiversity Heritage Library | Additional Collections
Search: Advanced Search
Anonymous User (login or join us)
Upload
See other formats

Full text of "Soft Circuits"

Rock Star Headphones 



Makej Projects 



Rock Star Headphones 

Written By: Syuzi Pakhchyan 



TOOLS: 

Needlenose pliers (1) 

Pencil (1) 

<ing pen 

Scissors (1) 
Sewing machine (1) 
Sewing needle (1) 
Soldering iron (1) 



PARTS: 

Fleece (1/2 yd) 

1c for top fabric 

Neoprene(1/2yd) 

for lining 

Conductive hook and loop (1) 

Conductive thread (1) 

LED (2) 





Headphones (1) 

as work just fine. 

Cellphone battery (1) 
Metal snaps (2) 
Thread (1) 
TapeM) 
Embroidery thread (1) 



SUMMARY 

The Rock Star Headphones require you to hack into an existing set of headphones and 
incorporate it into a new design. The Rock Star will also have two square LEDs sewn onto 
the exterior of the earwarmers. The LEDs have both an aesthetic function and a practical, 
safety function: making the wearer visible for jogging or biking at night. The circuit 
incorporates a soft switch made from conductive hook and loop, so the LEDs turn on only 



) Make Projects 



www.makeprojects.com 



Pagel of 10 



Rock Star Headphones 

when the headphones are worn. 



) Make Projects www.makeprojects.com Page 2 of 1 



Rock Star Headphones 



Step 1 — Cut the template. 




• Download the templates from 
Documents and print them out. 

• Using a marking pen, trace 
Template A onto the interior of the 
suede. Repeat for the inner 
neoprene lining. Cut out the 
template. 

• Then trace Template B onto the 
neoprene, and cut the template out. 
Set aside. This will be the battery 
pocket piece. 



) Make Projects 



www.makeprojects.com 



Page 3 of 10 



Rock Star Headphones 



Step 2 — Sew the circuit path. 




• Trace the positive and negative conductive paths onto the interior of the suede. Place a 
bobbin of conductive thread in the sewing machine, and a spool of regular thread the same 
color as the suede in the spool pin. 

• Machine-stitch both conductive paths along the traces, making sure that the conductive 
thread is at the bottom of the fabric. Leave about 5" of loose thread at the beginning of the 
path. Knot and cut the extra thread at the end of the path. The upper conductive path will 
be the positive path. The lower conductive path will be the negative path. 

• Replacing the conductive thread bobbin with ordinary thread, machine-stitch the loop 
pieces (soft side) of the hook and loop horizontally to the top and bottom right corners of 
the suede. The loop pieces should be sewn on the top of the suede. 

• Thread a sewing needle with the loose conductive thread from the negative path. Sew 
through the loop piece several times, making a connection between the negative path and 
the bottom loop. Knot and cut the conductive thread. Repeat for the upper loop piece, 
sewing the positive path to the upper loop. 



) Make Projects 



www.makeprojects.com 



Page 4 of 10 



Rock Star Headphones 
Step 3 




) Make Projects 



www.makeprojects.com 



Page 5 of 10 



Rock Star Headphones 

• Cut two 1"x4" pieces of neoprene. Place the bobbin of conductive thread back into the 
machine. 

• Machine-stitch a 4" conductive path lengthwise about 1/4 " from the edge. Machine-stitch 
a 2" conductive path about 1/4" from the opposite edge. Repeat for the second piece of 
neoprene. 

• Pierce the leads of an LED with the positive leads facing up through the front of the suede 
at your desired location. 

• Place the suede piece wrong side up. Grab one of the neoprene pieces. Pierce the leads of 
the LED through the neoprene in between the 2 conductive paths. The best way to 
determine which are the positive and negative leads is to refer to the datasheet or wire 
them temporarily using alligator clips. The conductive path on the neoprene should be 
facing up. Using needlenose pliers, bend the leads flush to the fabric. Repeat for the 
opposite side. 

• Using conductive thread, hand-sew the positive lead of the LED to the long conductive 
path on the neoprene. Using a separate piece of conductive thread, sew the negative lead 
of the LED to the short conductive path on the neoprene. Make sure that the conductive 
threads from the positive and negative LED leads never touch. 

• Using conductive thread, hand-sew the long conductive path on the neoprene to the upper 
positive conductive path on the suede. Using a separate piece of conductive thread, sew 
the short conductive path on the neoprene to the lower negative conductive path on the 
suede. Repeat for the second LED. 

• The positive lead of the LED should now be connected via the neoprene to the upper 
positive conductive path terminating at the positive loop piece and vice versa, with the 
negative lead connected via the neoprene to the lower negative conductive path 
terminating at the negative loop piece. 

• NOTE: In this example, we have used high-flux LEDs. High-flux LEDs have 4 legs 
— 2 positive (anodes) and 2 negative (cathodes). You can substitute the high-flux 
LEDs with typical LEDs. If you are using typical LEDs, curl the negative LED lead (the 
shorter one) into a loop. Mark it with a black marker to help you distinguish the negative 
lead from the positive. Then curl the positive lead. 



) Make Projects www.makeprojects.com Page 6 of 1 



Rock Star Headphones 



Step 4 — Sew the battery pack. 





HH^^fetf-^ 




9; ' 






IB : 

V 



• Take the cellphone battery, and solder a female snap to the positive lead and a male snap 
to the negative lead. 

• NOTE: Some cellphone batteries have a third signal lead, typically coated in blue. If 
you can't distinguish the positive and negative leads (typically positive is red and 
negative is black), use a multimeter. 

• Place the neoprene right side up with the ear flap facing down. Using ordinary thread in the 
bobbin, machine-stitch the hook pieces (prickly side) of the hook and loop horizontally to 
the top and bottom right corner of the neoprene. Using conductive thread in the bobbin, 
sew a path about 1" to the left and 1" down (making an "L" shape) from the upper hook 
piece. Using conductive thread, end the path by sewing on a male snap. 

• Using conductive thread in the bobbin, sew another path about 1" to the left and 1" up 
(making an "L" shape) from the lower hook piece. Again using conductive thread, end the 
path by sewing on a female snap. 

• Fold the battery pocket piece along its hemlines. Machine-stitch the pocket piece next to 
the hook pieces, covering the conductive paths and snaps. 

• NOTE: The path must be connected to the hook piece. Begin the path inside the 
hook piece. 



a 



) Make Projects 



www.makeprojects.com 



Page 7 of 10 



Rock Star Headphones 



Step 5 — Embroider the headphones. 




• Personalize your headphones by embroidering custom designs. For those not particularly 
skilled in the craft of embroidery, you can't go wrong with a simple five-point star. 

• Using a tracing pen, trace a five-point star on top of the suede. Using embroidery thread, 
embroider the star. Repeat for the opposite side. 



) Make Projects 



www.makeprojects.com 



Page 8 of 10 



Rock Star Headphones 



Step 6 — Sew the headphones. 




• Using needlenose pliers, carefully deconstruct the headphones until you have the 2 
speakers loose from their housing. 

• Take the earpiece covers and place the neoprene piece right side up. Using ordinary 
thread, hand-stitch one of the earpiece covers to the center of the curved ear flap. Repeat 
for the other side. 

• Turn the neoprene over, placing it wrong side up. Using a utility knife, slice down the 
center of the back of the earpiece cover, being careful not to slice through the earpiece 
cover itself. Repeat for the second earpiece cover. 

• Slip the headphone earpieces into each slot. Adjust the wires so that the audio plug is 
located near the hook and loop, and extending from the bottom of the neoprene. You can 
temporarily hold the wires in place with tape. Once you have positioned the wires 
appropriately, use ordinary thread to hand-stitch sections of the wire in place. 

• Pin the neoprene lining to the upper suede piece. Machine-stitch the 2 pieces together, 
making sure to sew over (not through) the wires extending from the audio plug. 



) Make Projects 



www.makeprojects.com 



Page 9 of 10 



Rock Star Headphones 



Step 7 




• Snap the battery into place, grab 
your MP3 player, and begin rockin 
out to your favorite tunes — nice 
and toasty! 



This project first appeared in Fashioning Technology by Syuzi Pakhchyan. 



st generated on 2013-01-15 10:47:40 PM. 



) Make Projects 



www.makeprojects.com 



Page 10 of 10